Cockroach Individual M3 2/19 Manual Swap Done, ZCP Trim, ZHP Wheel and Illumin Knob

[naskhoda]

🔥 dope

[samthejam]

Another unexpected update! This week, while I was at work, I got a call from a friend. He told me he was picking up the alignment machine from the shop where I used to work in high school. The computer was broken, and the owner decided to replace it with a two-post lift instead. He has an alignment guy but doesn’t like dealing with it himself.

Along with that, the owner wanted to clean out the shelves—over a decade's worth of collected stuff—so my friend mentioned that he was giving away a bunch of E46 M3 interior parts.

This happened to be the same shop that stripped out my dad’s M3 years ago. So after helping them load up the (sketchy) alignment lift, I started digging around. The Find


I ended up uncovering:

• My dad’s old rear door cards
• His radio surround trim
• Front Grey ZCP door handles
• Three coupe door cards
• All of his old headliner A, B, and C pillar pieces

The blue bin ended up holding all of these neatly organized. I even found his name on old registration papers, a dealer inspection from 40K miles, and some cigar business cards—all tucked away in the armrest, which unfortunately had broken while in storage.

You can actually see his old headliner sitting up there:


Zcp trim by Sam DaJam, on Flickr
Untitled by Sam DaJam, on Flickr


Zcp trim by Sam DaJam, on Flickr




Zcp trim by Sam DaJam, on Flickr

The rear door cards were the ones I used to sit in when he dropped me off at elementary school. I’ve always preferred the ZCP trim, and since my own door cards had messed-up armrests, I was excited to swap everything over.
Zcp trim by Sam DaJam, on Flickr
Zcp trim by Sam DaJam, on Flickr

Zcp trim by Sam DaJam, on Flickr

Untitled by Sam DaJam, on Flickr
Only one broken clip on his old panel! Salvage Yard Run


The next day, I went to the yard. Out of all the Houston self-service salvage yards, there was only one coupe with a black interior that I knew of. It had been there since January 2nd, so I had low expectations. Sure enough, the manual swap and any decent black interior bits were already gone.

While working on my door cards, I noticed an issue: when it rains, my driver’s door card fills with water—usually a vapor barrier problem. Since I had everything apart, I was able to confirm that was the case.

Then, I looked up at the headliner of the car and realized it was a slicktop—super rare on a 330i with leather interior and electric seats.

I knew I had to grab it.


Zcp trim by Sam DaJam, on Flickr
Hauling It Home


I had to call my wife to bring the Montero because there was no way I was driving home with it in the E46.

With only a T20, 10mm, and two flatheads, I had to borrow a Phillips from someone at the yard. I originally packed light to avoid buying stuff I didn’t need—but when I saw this slicktop, there was no way I could pass it up.

Zcp trim by Sam DaJam, on Flickr

[samthejam]

Untitled by Sam DaJam, on Flickr
Untitled by Sam DaJam, on Flickr
Untitled by Sam DaJam, on Flickr
Untitled by Sam DaJam, on Flickr

Ladies and Gentleman, I believe it is time...

Almost everything here is used, so that's fun but why new when used will do. I refreshed the shift bushings with OE at least.



I believe I have everything, I did the GPS delete by manually editing the bin file. Than Jay popped it into his Ecuworx for me and did the rest of the manual changes needed.

I modified the .xdf for this and here is some notes I have as the ones in the manual swap thread were kinda confusing.

MSS54HP .bin Modications:

1) Modify K_SKRAFTS_CONTROL to 0x02

• Location: 0x4028
• Edit: Set to 0x02 → 2 (default is 0x01 → 1)
• Purpose:
  • The DME currently treats the clutch sensor and Gear Identification Sensor as one, since they are wired in serial.
  • This setting aligns the behavior with how the Z3M is wired, where the clutch switch is directly connected to the DME.
  • With this change, the DME will recognize that the circuit can still be closed even when the car is in neutral with the engine running.

2) Modify K_S_GANG_LL_ED to 0xFFFF

• Location: 0x5952 on 2001/2701
• Edit: Set to 0xFFFF → 65535 (default is 0x0032 → 50)
• Purpose:
  • This prevents the DME from throwing an error when the car is idling with the clutch engaged (up).
  • It essentially adjusts the logic for idle behavior, ensuring that the ECU does not falsely detect an issue when the car is stationary.

3) K_MD_MIN_VERH_KRAFTS

• Purpose: This parameter defines the minimum torque threshold required for certain powertrain functions to be active.
• Edit: Set to 0xA0 → 160 (default is 0x80 → 128)
• Location:
  • 0x67E0 on MSS54
  • 0x88A2 on MSS54HP
• Default Values:
  • US cars: 0x80 (128 in decimal)
  • Euro cars: 0xA0 (160 in decimal)

The plan is to throw it all in this weekend, flash it and see what happens. I am most nervous about removing the Plenum as I haven't done that yet.

[samthejam]

or example changing Vehicle Order (VO), and adding/removing options from Modules. NCS Dummy helps understand what the options mean in English.

Steps:

1) Using NCSExpert, Remove $793 (this is the SMG option by the way) from the Vehicle Order in AKMB and ALSZ modules then write the new Vehicle Order back to the AKMB and ALSZ modules.

2) Modules to Code With NCSExpert, note in brackets is the NCSExpert name for the modules)
- DSC (DSC), change from SMG to Manual
- Instrument Cluster (AKMB) removing any SMG options, then adding any manual options that are available to select
- Immobiliser (AEWS) - remove press Brake Pedal To Start option
-
NOTE: As stated above, NCSDummy makes doing the changes above much easier

https://www.youtube.com/watch?v=FiBr1h9j0bU

[samthejam]

1st. For people who don't know anything about coding: The central coding key (ZCS) or vehicle order(FA or VO) is like the DNA of the car. The build date, basic equipment and optional equipment are listed inside here. It's saved redundant in 2 modules and has one simple funcion.. The computer that's going to program or code the module(s) reads it and then determines how to deploy the software/coding to suit that specific car.\

2nd. Because of the vehicle order only being changed for manual transmission, you should only code the relevant module(s) after you write the FA to the modules storing it, so in this case you should have only coded the kombi (AKMB) instead of the whole car and you would be all set. Processing the whole car can be quite dangerous. As failure to communicate with a module during coding actually can destroy a module.. ask me how i know Because of that you should only code modules that actually need to be coded and leave the rest alone, to reduce the risk

[George Hill]

I would be most concerned about the shift arm bushing bracket. No issue using a used one like you are but with the rear tab mostly cut off I think you are going to struggle to fasten it securely. I would consider getting another one unless you are going to weld it and if so pull the carpet so its doesn't catch on fire.

[samthejam]

I would be most concerned about the shift arm bushing bracket. No issue using a used one like you are but with the rear tab mostly cut off I think you are going to struggle to fasten it securely. I would consider getting another one unless you are going to weld it and if so pull the carpet so its doesn't catch on fire.

Yes the plan is to weld it and try and make the carpet not catch on fire. I think I am going to just remove the center console and cut accordingly. Then just place that piece of carpet back in.

[samthejam]

oding Vehicle Order
Depending on what year your car is, this part is slightly different. I'll use 50'sKid's video as a reference, as this is what helped me successfully remove the option code from my car. The newer cars have the "vehicle order", and older cars have a "zcs number". Both of these store the list of optional and base equipment for the car. If your car came with heated seats, then this is depicted in your vehicle order or ZCS. This is used by the whole car to determine how the computers behave, and what their default programming is. If your car was produced before 08/2001, then you have the ZCS format, otherwise, your car is coded through the "FA". You can find the production date of your car by going to RealOEM and entering the last 7 digits of your VIN.

Start by loading the expert profile in NCS expert. Click file -> Choose Profile. Pick the Expert mode profile (sometimes referred to Expertmodus or something along those lines)

Click VIN/ZCS/FA, then ZCS/FA f. ECU. Choose E46, then either the AKMB or ALSZ, unless your car uses ZCS, in which case you read the EWS or KMB. This will read your cars current FA (Vehicle Order) or ZCS from whichever module you select.


For Cars newer than 08/2001
Once this is done, click "Enter FA", select E46 and then enter your vin. If it's partially wrong, don't worry about that because it's meant to be. Only the last 7 characters should be correct. Hit OK and you should see this window.

Your option codes will be very different as this image is from a 325. Now, scroll down in the list until you find the "$793" code, select it and then press delete on your keyboard. This should remove the SMG option code from the list. (skip down to "After adjusting the vehicle option code list")


For Cars older than 08/2001
Now, click on "Enter ZCS", select E46 and enter your vin. If it's partially wrong, don't worry about that because it's meant to be. Only the last 7 characters should be correct. Hit OK and you should see this window.

You only need to touch the SA section, and start by removing the very last digit from the number. Now, subtract 8 from what is now the last digit, such that if your number is 0-8, you replace it with 0. 9→1, A→2, B→3, C→4, D→5, E→6, F→7. Once this is done, make sure to have "Calculate Checksum" checked before clicking ok.


After adjusting the vehicle option code list
Now click ok > Back > Process ECU > AKMB (or just KMB for older cars). Once you've done this, you should see the "JOBNAME" is set to "SG_CODIEREN". Click change Job, then select "FA_WRITE" (or "ZCS_SCHRIEBEN"), which will code the new FA (ZCS) to your module. Now click Execute Job, and you should eventually see "Job ended". This indicates that the write was successful. If your car is older, click "change ecu" and select the EWS, and click execute job. Otherwise, click "change ecu", select the ALSZ, and repeat this FA_WRITE by clicking execute job.

Now that your new vehicle order is written to your car, you can reprogram each individual module to their default programming, which is determined by the vehicle order. Since your vehicle order is now different, that also means that your default programming is different. Using the "expert" profile in NCS, repeat the same steps to read your FA from the AKMB or ALSZ (or KMB/EWS), then Back > Process ECU > AKMB (or KMB). Now you should see the "SG_CODIEREN" as the JOBNAME. Click execute job to write the default coding to the module. Repeat this job on the AKMB (KMB), MK60 (DSC), and the ALSZ (EWS). At this point, restart the car and you should see that everything is working properly, but you'll still have a gear light on the dash.

Open INPA, and navigate to the DME, clear error codes and adaptations, then read them back. Also clear codes for the Instrument Cluster, EWS (vehicle immobilization), and the MK60 (assuming you have a later model). Once these error codes are cleared, you should be able to turn the car off and back on again and see no gear light on the dash. If you still have dash lights, go around to different modules and clear their errors and see if they return. Now you should be all set!

With this, your car should be completely coded with manual software, and there is practically no difference between this and the default software on a manual car (other than the modifications you may have made). Now when scanned, your car will show itself as a manual, and you won't get any SMG-related error codes that might cause the car to enter limp mode.


Credit to p0lar and terraphantm, as their work on these cars is what provided me the ability to put all of this together. I referenced their posts a lot, and this post is essentially a condensation of their work. I just put it together in a hopefully comprehensive fashion to allow anyone to reprogram their car. If any of this info is wrong or you have a suggestion on an improvement I can make, let me know so I can correct it.

[bigjae46]

Yes the plan is to weld it and try and make the carpet not catch on fire. I think I am going to just remove the center console and cut accordingly. Then just place that piece of carpet back in.

Might work...only one way to find out...but you can put a thick slab of steel on the interior side of the weld and cover it with a fiberglass tarp. The steel should absorb a lot of the heat and fiberglass won't melt. Or have someone inside of the car hold the carpet up for awhile.

[samthejam]

I was able to get my free Recaro Profi in that came with my SSRs, the seat didn't come with the cusions but I was able to find a pair on Ebay of recovered cushions that someone was selling off their seats. Good enough for now. I also went with a manual rail on this side.

Untitled by Sam DaJam, on Flickr

I was also able to resolve my communication errors with various modules. I needed to solder the pins in my OBD Cable. So I am much more confident in the coding this weekend for the manual swap.


Untitled by Sam DaJam, on Flickr
Untitled by Sam DaJam, on Flickr
Untitled by Sam DaJam, on Flickr

[samthejam]

So I was able to get the manual swap done. Total time was about 11 hours. I was able to do the swap and drive to Huntsville on the same day.
Untitled by Sam DaJam, on Flickr
Untitled by Sam DaJam, on Flickr
Untitled by Sam DaJam, on Flickr
Untitled by Sam DaJam, on Flickr
Untitled by Sam DaJam, on Flickr
Untitled by Sam DaJam, on Flickr
Untitled by Sam DaJam, on Flickr
Untitled by Sam DaJam, on Flickr
Untitled by Sam DaJam, on Flickr
Untitled by Sam DaJam, on Flickr


Untitled by Sam DaJam, on Flickr
The biggest complications were the bellhousing bolts, welding the shifter bracket, and the clutch soft line.

- I am familiar with how fun bellhousing bolts are. However, even with all the extensions, and wobblies I could not get to the 3 bellhousing bolts. My father does not have a pole jack, so couldnt jack engine up. What I did was lower the rear subframe bolts and that was enough to get it done. I was not very happy to do it that way but it was the ticket, I need to buy him a pole jack.

- The shifter bracket, jesus christ the sound deadning they have sprayed on compared to the 2001 M3 Vert I pulled my bracket from. Not only was it an absolute nightmare to clean, the carpet was not catching on fire. It was that stupid sound deadning and it was awkward to get in there. I was able to get the rear welded in and if I am being honest there are war crimes holding it up. However it doesn't seem to flex at all when shifting, so we'll see if it fatigues it appears solid.

- The clutch soft line, I am an idiot and didn't get a new one. Of course I used a used one, which is fine the line is fine. I got a new OE hardline. However I am pretty sure the soft line is from Non M, it is stretched out. Not pinched but it is under tension. So I need to order a M3 one, I am assuming they are different. As of writing this I have no checked the part number, if they are not different well shit.

I went to look it up, https://www.fcpeuro.com/products/bmw...774267#fitment they are the same so the monkey that installed it needs to check orientation of the hardline or something else


So that is something I need to look into.

- The coding was fun, as my NCS Expert was full german not just the job function options all of it. Even the buttons on the bottom, so for instance "process ECU" was in German. I did a good job studying this before I did it, and had not planned for that. That just made it scary but I had screenshots of the buttons in English and was just heavily double checking what I was doing as I didn't want to process all modules.


I drove home from Huntsville that night no issues.


Some other fun notes I was able to fix some issues while the plenum were on. Half the hose clamps were on incorrectly, they were around what I believe is an adjustment for the ITBS on the bottom right hand corner and not fully aropund the boots. I was able to find out why my oil pressure warning light has never worked. Someone had unplugged it. One of the Idle control valve hoses was zipties intead of hose clamped. The rearmost lower plenum hose I believe was just plain disconnected. I also saw it has a parts store starter in there.



Next day I went to Austin to get the remaining ZCP trim I bought from him as well as the ZHP trim. I was not expecting to make that trip as I expected the swap to take longer, but I wanted to shake the car down and a 6 hour roundtrip should give me an idea.

Untitled by Sam DaJam, on Flickr
Untitled by Sam DaJam, on Flickr
Untitled by Sam DaJam, on Flickr
Untitled by Sam DaJam, on Flickr

Thank You George! I got home at 10 pm, I was able to clean the Alcantara wheel fairly okay. It'll do. Very happy to have been able to have the full zcp trim.
My friend Ale went as well in his E36 and he was able to get the sport button for his S54 E46 Wagon, the car has been done for awhile but he has been looking for the correct heated seats, premium sound, non vert M3 button panel.

[samthejam]

[samthejam]

Got the new ZHP wheel in and it came out much better than the last one I had in my free30i. I mainly just used warm water and a toothbrush this time instead of the Sonax cleaner and a microfiber. I tried some regular home soaps, dish soap and hand soap didn't seem to make too much of a difference. Just a lot of light brushing and warm water.

Also got the shift knob wired up using a pigtail from a parts car.

Maybe one day I can find a good used ZCp/comp wheel, but for now this will do.

Untitled by Sam DaJam, on Flickr
Untitled by Sam DaJam, on Flickr